Anti-theft pusher with incremental distance detection

ABSTRACT

A retail merchandise pusher is configured for sliding along a pusher assembly track. The pusher assembly is mountable to a retail merchandise shelf. The pusher includes a housing, a spring drum rotatably mounted within the housing, and a coil spring mounted to the spring drum. The coil spring is coilable and uncoilable upon rotation of the spring drum. A controller is coupled to a sensor arrangement within the housing. The sensor arrangement has a spring drum sensor for detecting rotation of the spring drum. A direction sensor detects a direction of rotation of the spring drum. An incremental distance sensor detects incremental movement of the pusher. The controller is configured to calculate, based on data from the sensor arrangement, a total distance and direction of travel by the pusher, and to generate an alarm when the pusher travels more than a threshold distance within a predetermined period of time.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a continuation of the co-pending U.S. patentapplication Ser. No. 16/839,667 filed Apr. 3, 2020, which claims thebenefit of U.S. Provisional Patent Application No. 62/830,045, filedApr. 5, 2019, the entire teachings and disclosures of which areincorporated herein by reference thereto.

FIELD OF THE INVENTION

This invention generally relates to a retail merchandise pusher, andmore particularly to a self-facing retail merchandise pusherincorporating anti-theft and inventory management technologies.

BACKGROUND OF THE INVENTION

Self-facing retail merchandise displays are generally known in the art.Once such typical display includes one or more pusher assemblies whichmay for example be situated on a retail merchandise shelf. Aconventional pusher assembly incorporates a pusher that rides along anelongated track. The track may be a single drop in track with a singlepusher slidable thereon, or it may be a structure defining multipletracks for receipt of respective pushers. A spring is connected betweenthe pusher and a leading edge of the track. The spring acts to bias thepusher forward along the track towards the leading edge thereof. A givendisplay may utilize multiple pusher assemblies arranged generally inparallel to on another.

A user can retract the pusher away from the leading edge of the trackand position items of retail merchandise (also referred to herein asproducts) in a linear row on top of the track and uncoiled portion ofthe spring, between the leading edge of the track and the pusher. Thebiasing force provided by the spring and exerted upon the pusher servesto bias the linear row of retail merchandise forward to ultimately“front face” the merchandise.

That is, when a customer removes the leading most item of merchandisefrom the linear row of merchandise, the pusher will be drawn forward bythe spring to index the row of merchandise forward so that the next itemof merchandise in the row is positioned proximate the leading edge ofthe track in an aesthetically pleasing manner. Such automatic frontfacing eliminates the necessity for retail store employees to manuallyface the merchandise, and thus ultimately reduces the cost of labor ofthe retailer.

The aforementioned pusher systems have been utilized in various retaildisplay environments. One example is a retail shelf. Typically, aplurality of pusher bodies and their corresponding tracks are arrangedin a side-by-side manner along the shelf. Each pusher and itscorresponding track are separated by dividers to maintain a plurality ofgenerally straight rows of merchandise that run from the front to theback of the shelf. Such a familiar configuration can be found in manyretail stores for selling hygiene items such as deodorant, as oneexample.

In another configuration, the pusher system may be embodied as astand-alone pusher tray. These trays may include means for mounting thetray as a cantilevered extension from another structure, such as a bar.These trays may also be situated directly on a retail shelf. Further,these trays may include side barriers which are adjustable so as toaccommodate merchandise of differing widths. Examples of these trays maybe readily seen at U.S. Pat. Nos. 9,254,049, 9,241,583, 8,720,702, eachof which is incorporated by reference herein in its entirety.

Loss prevention is a continuing problem in the retail industry. Currentanti-theft systems involve locking up merchandise behind counters thatare far away from other related merchandise, or locking up themerchandise in secure cabinets that are closer to where the relatedmerchandise is generally stored.

Heretofore, there have been limited attempts at incorporating anti-thefttechnology into pusher systems themselves. Such attempts, whilesufficient for a majority of loss prevention scenarios may not detectvery small movements of the pusher, e.g., where very small merchandiseis contained in the pusher system such that removal of one item or evenseveral creates a very small movement in the pusher.

Other challenges arise in self-facing retail merchandise displays withregard to inventory management. Because the merchandise contained insuch displays is typically high purchase volume merchandise, e.g.,deodorants, razor blades, medicines, etc., it is not uncommon for one ormore rows of the display to become completely empty for some time beforebeing restocked. Accordingly, such displays must be routinely inspectedby store personnel to ensure that they have adequate stock levels. Thisinspection may be overlooked from time to time in the event the store isunderstaffed, or adequately staffed but very busy. Such manualinspection, while necessary, diverts store personnel from otherpotentially more pressing activities such as customer service.

Accordingly, there exists a need in the art for a retail merchandisepusher display, pusher assembly, and pusher incorporating a system forretail stores that will deter theft and enhance inventory management ofsuch displays.

BRIEF SUMMARY OF THE INVENTION

In one aspect, embodiments of the invention provide a retail merchandisepusher configured for sliding along a track of a pusher assembly, wherethe pusher assembly is mountable to a retail merchandise shelf. Thepusher includes a housing, a spring drum rotatably mounted within thehousing, and a coil spring mounted to the spring drum. The coil springis coilable and uncoilable upon rotation of the spring drum. Acontroller is coupled to a sensor arrangement carried within thehousing. The sensor arrangement includes a spring drum sensor fordetecting rotation of the spring drum. A direction sensor detects adirection of rotation of the spring drum, while an incremental distancesensor detects an incremental movement of the pusher. The controller isconfigured to calculate, based on data from the sensor arrangement, atotal distance and direction of travel by the pusher, and alsoconfigured to generate an alarm when the pusher travels more than athreshold distance within a predetermined period of time.

In a particular embodiment, the alarm is at least one of a visual,audible, or RF signal. The controller may be coupled to an output devicedisposed in the housing, where the output device is configured toproduce the alarm as a visual or audible signal. Furthermore, thecontroller may be coupled to a transmitter disposed in the housing,where the transmitter is configured to wirelessly transmit data to aremote receiver. The aforementioned data includes at least one of analarm status, and the total distance and direction of travel by thepusher.

In particular embodiments, the controller is configured to transmitinformation, based on data from the sensor arrangement, wherein theinformation includes an inventory status for the pusher assembly. Asused in this application, the term “inventory status” or “stock status”relates to the number of merchandise items remaining in a particularpusher assembly. The movement of the pusher, which may indicate eitherthe replenishment or the removal of goods from the pusher assembly,typically results in a change of the inventory status for the pusherassembly. In more particular embodiments, the controller comprises amicroprocessor.

In some embodiments, the spring drum sensor includes a pair of opposedelectrical contacts and a tab extending from the spring drum, the tabrotatable with the spring drum, wherein the tab is arranged to bias oneof the pair of opposed electrical contacts into contact with the otherone of the pair of the opposed electrical contacts at each completerevolution of the spring drum.

In other embodiments, the direction sensor includes a first electricalcontact, a common electrical contact, and a second electrical contact,the common electrical contact interposed between the first electricalcontact and the second electrical contact. In a further embodiment, adistal end of common electrical contact is intermittently in contactwith gear teeth formed on an outer periphery of the spring drum suchthat the common electrical contact is biased by the gear teeth intocontact with the first electrical contact when the spring drum rotatesin a first direction, and biased by the gear teeth into contact with thesecond electrical contact when the spring drum rotates in a secondrotational direction opposite the first rotational direction.

In certain embodiments, the incremental distance sensor includes asensing gear in contact with the spring drum, and a slotted disc mountedto the sensing gear, the incremental distance sensor further comprisinga light sensor arrangement configured to produce and detect a beam oflight. In a further embodiment, a peripheral region of the slotted discis movable through a sensing region through which the beam of lightextends, wherein the peripheral region includes a plurality of slotsformed therein, wherein the plurality of slots sequentially pass throughthe sensing region as the sensing gear rotates such that the beam oflight alternately passes through and is blocked by the plurality ofslots. The light sensor arrangement may include a light emitter locatedon a first side of the slotted disc, and a light sensor located on asecond side of the slotted disc opposite the first side, the lightsensor arranged to detect the beam of light emitted by the lightemitter.

In more particular embodiments, the light emitter is arranged to emitthe beam of light such that it is perpendicular to a plane of rotationdefined by the slotted disc. In other embodiments, the coil spring isconfigured to bias the housing toward one end of the track. Further, thepusher may be configured to permit a user to set or adjust at least oneof the threshold distance and the predetermined period of time. In someembodiments, the pusher includes a reset control to set a zero positionfor the controller, the zero position indicating that no merchandise iscontained in the pusher assembly such that the pusher is at an end ofthe track.

In another aspect, embodiments of the invention provide a pusherassembly configured for mounting to a retail shelf, the shelf having afront and a back, wherein retail merchandise situated near the front ofthe shelf is removable from the pusher assembly. The pusher assemblyincludes a track, and a pusher mounted to the track. The pusher isslidable toward and away from the front of the shelf. The pusherincludes a controller coupled to a sensor arrangement for detectingmovement and a direction of travel by the pusher. The controller isconfigured to calculate, based on data from the sensor arrangement, atotal distance traveled by the pusher along the track. The controller isfurther configured to generate an alarm when the pusher travels morethan a threshold distance within a predetermined period of time.

In a particular embodiment, the sensor arrangement includes a springdrum sensor, a direction sensor, and an incremental distance sensor. Inone embodiment, the spring drum sensor includes a pair of opposedelectrical contacts and a tab extending from a rotatable spring drum ofthe pusher, the tab rotatable with the spring drum, wherein the tab isarranged to bias one of the pair of opposed electrical contacts intocontact with the other one of the pair of the opposed electricalcontacts at each complete revolution of the spring drum.

In another embodiment, the direction sensor includes a first electricalcontact, a common electrical contact, and a second electrical contact,the common electrical contact interposed between the first electricalcontact and the second electrical contact. The incremental distancesensor may include a sensing gear in contact with the spring drum thegear including a slotted disc mounted to the gear, the incrementaldistance sensor further comprising a light sensor arrangement configuredto produce and detect a beam of light.

In certain embodiments, the alarm is at least one of a visual, audible,or RF signal, and the controller is coupled to a transmitter configuredto wirelessly transmit data to a remote receiver. The aforementioneddata includes at least one of an alarm status, and the total distanceand direction of travel by the pusher. The pusher may be furtherconfigured to permit a user to set or adjust at least one of thethreshold distance and the predetermined period of time, and to includea reset control to set a zero position for the controller. The zeroposition indicates that no merchandise is contained in the pusherassembly such that the pusher is at an end of the track. The controllermay be configured to provide, based on data from the sensor arrangement,an inventory status of the pusher assembly.

In yet another aspect, embodiments of the invention provide a retailmerchandise display system for self-facing retail merchandise. Theretail merchandise display includes a shelf, and at least one pusherassembly mounted to the shelf. The at least one pusher assembly includesa track, and a pusher slidable along the track. The pusher assemblyincludes a controller coupled to a sensor arrangement. The controller isconfigured to calculate, based on data from the sensor arrangement, alarge-scale movement of the pusher, and an incremental movement by thepusher, where the controller is configured to generate a local alarmwhen a total distance traveled by the pusher, where the total distanceis equal to a sum of the large-scale movement and the incrementalmovement, is greater or equal to a predefined distance. The pusherincludes a transmitter operable to wirelessly communicate the totaldistance traveled by the pusher. A receiver is remotely located from thepusher, and configured to receive a wireless signal from thetransmitter, and configured to generate a remote alarm in concert withthe local alarm.

In certain embodiments, the local and remote alarms are at least one ofvisual or audible alarms. In other embodiments, the at least one pusherassembly includes a plurality of pusher assemblies, wherein each one ofthe plurality of pusher assemblies wirelessly communicate with thereceiver. Still, in other embodiments, the receiver includes an RFreceiver, an audio speaker, and a Wi-Fi module configured to transmitdata received from the pusher. Further, the wireless signal may be an RFsignal.

In some embodiments, the sensor arrangement includes a spring drumsensor, a direction sensor, and an incremental distance sensor. Further,the receiver may be configured to transmit data received from the pusherto a computer or mobile device, such that the data allows the computeror mobile device to display information regarding the pusher assembly.Moreover, the information regarding the pusher assembly may include atleast one of an alarm status, and inventory status, and a position ofthe pusher.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a perspective view on exemplary embodiment of a retailmerchandise display system that incorporates a pusher assemblyconstructed in accordance with an embodiment of the invention;

FIG. 2 is a side view of the retail merchandise display system of FIG.1;

FIG. 3 is a schematic illustration of the operational topology of theretail merchandise display system, according to an embodiment of theinvention;

FIG. 4 is a perspective exploded view of a pusher of the pusherassembly, according to an embodiment of the invention;

FIG. 5 is a side view of the pusher, with a portion of its outer housingremoved, according to an embodiment of the invention;

FIG. 6 is a perspective view of the pusher, with a portion of its outerhousing removed, according to an embodiment of the invention;

FIG. 7 is another perspective view of the pusher, with a portion of itsouter housing removed, according to an embodiment of the invention;

FIG. 8 is a partial front view of an incremental distance sensor of thepusher, according to an embodiment of the invention; and

FIG. 9 is a flowchart of the motion detection and alarm functionality ofthe pusher, according to an embodiment of the invention.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, the same illustrate an exemplary embodimentof a retail merchandise display system that incorporates a pusherassembly. The pusher assembly includes a pusher which includes a new andinventive sensor arrangement for detecting and calculating relativelysmall movements of the pusher. Such a configuration is highlyadvantageous for loss prevention and inventory management purposes,particularly loss prevention and inventory management of relativelysmall products.

Indeed, the high resolution of the distance detection of the pusherenables an accurate calculation of a number of products removed from theretail merchandise display in a single movement cycle or in a givenperiod of time. For example, a movement cycle (i.e., a continuousmovement of the pusher) reflecting a relatively long distance traveledby the pusher is indicative of a number of products removed in a singlemovement of the pusher. As another example, a large number of separatemovement cycles during a relatively short period of time is alsoindicative of a number of products removed from the display. In eithercase, each is indicative of a potential theft event. The systemdescribed herein is operable to generate one or both of a local and aremote alarm when such potential theft conditions are met. Further, thesystem described herein also communicates the information it collectsregarding pusher movement for purposes of managing the inventory of thatparticular pusher assembly.

With particular reference to FIG. 1, the same illustrates an exemplaryembodiment of a retail merchandise display system 20 (also referred toherein as display 20). Display 20 included one or more pusher assemblies22 mounted to a shelf 24. Each pusher assembly 22 includes a pusher 26that is slidable along a track 28. Each pusher 26 houses a coil springdescribed below which attaches to shelf 24 directly, or as shown in theillustrated embodiment, to an external structure that in turn is mountedto shelf 24 such as a mounting rail 30. The pusher 26 is biased by thiscoil spring 80 toward one end of the track 28. In the embodiment shown,the pusher 26 is biased by this coil spring 80 toward the mounting rail30, i.e., from the back of shelf 24 toward the front of shelf 24.

As described in greater detail below, pusher 26 houses a sensorarrangement which is operable to calculate the distance traveled bypusher 26 along track 28, and to determine the direction of such travel,e.g., from the back to the front of shelf 24, or from the front to theback of shelf 24. In event that such movement is indicative of apotential theft event, pusher 26 is also operable to generate a localalarm at pusher 26, and/or a remote alarm at a receiver 40 of display 20located remotely from the remainder of display 20. The term “alarm” asused herein should be taken to mean any audible or visual cue designedto draw attention to display 20, such as beeps, tones, prerecordedmessages, flashing or continuous lights, etc., but is also intended toinclude any electronic signal which could be used to serve as a warning.Such remote alarm functionality is particularly advantageous as receiver40 may be located with security or other personnel that can readilyrespond to a potential theft event. The remote alarm generated byreceiver 40 may be simultaneous and in concert with the local alarmgenerated by the pusher 26.

Still referring to FIG. 1, two pusher assemblies 22 are illustrated.However, display 20 may utilize fewer or greater pusher assemblies.Indeed, in the case of smaller products, a relatively large number ofpusher assemblies 22 may be situated on shelf 24. Further, display 20may optionally also include a plurality of dividers 32 as shown, forkeeping adjacent rows of product confined from one another. Each divider32 may also include its own integrated front stop 34 as shown, forstopping the forward motion of products as they are biased by pusher 26.Alternatively, a front stop may be mounted directly to shelf 24 (or beformed by the shelf itself) or alternatively to mounting rail 30. Withthe foregoing description in hand, it will be readily recognized thatmounting rail 30, dividers 32, and front stops 34 are optionalcomponents that may take on different forms or may be omitted entirelywithin the scope of the invention described herein.

Turning now to FIG. 2, pusher assembly 22, and particularly pusher 26,is operable to bias products 42 forward, i.e., in direction 50 shown inFIG. 2. The leading product 42 is removable from display 20 as shown. Ina potential theft event, multiple or even all of products 42 may beremoved in a single action, or in multiple quick successive actions. Ineither case, pusher 26 will move a relatively large distance forward indirection 50. As introduced above and described below, pusher 26 isoperable to determine the distance it has traveled, and generate anappropriate alarm when the distance is beyond a predetermine threshold.As discussed herein, the alarm may be a visual alarm, audible alarm, orelectronic signal such as a wireless or RF signal which could serve as awarning to the system user. Further, the alarm may be any combination orall of the aforementioned types.

With reference to FIG. 3, pusher 26 incorporates a new and inventivesensor arrangement for achieving the foregoing functionality. Thetopology shown in FIG. 3 depicts this sensor arrangement and additionalcomponentry necessary to achieve the functionality herein. Inparticular, the sensor arrangement includes a spring drum sensor 62, adirection sensor 64, and an incremental distance sensor 66 which incombination determine the distance and direction traveled by pusher 26.Each of the foregoing components of the sensor arrangement is inoperable communication with a controller 60. Controller 60 may forexample be a microprocessor, or any other firmware, hardware, orsoftware necessary to achieve the functionality herein.

Controller 60 is coupled to a local power supply 68 and an output device70. Local power supply 68 provides electrical power to the controllerand/or sensor arrangement to achieve the operation described herein.Output device 70 produces the above-introduced local alarm, and as such,may be embodied as any device capable of producing such an alarm. Aswill be explained in more detail below, the controller 60 is configuredto calculate, based on data from the sensor arrangement, a totaldistance and direction of travel by the pusher 26, and to generate analarm when the pusher 26 travels more than a threshold distance within apredetermined period of time. As will be explained below, the pusher 26may include controls to allow the user to adjust the threshold distanceand the predetermined period of time.

Controller 60 is also in communication with a transmitter 72 whichwirelessly sends the distance and direction of travel information, alarmstatus, and any other information collected by controller 60 to receiver40, shown schematically in FIG. 3. As used in this application, the term“alarm status” refers to whether or not an alarm is being triggered orhas been triggered by the controller 60. This wireless communication mayuse any known radio frequency (RF) communication protocol. The datatransmitted from the controller 60 to the receiver 40 may include atleast one or all of an inventory status, alarm status, and totaldistance and direction of travel by the pusher 26. In at least oneembodiment of the invention, there are a plurality of pusher assemblies22, wherein each one of the plurality of pusher assemblies 22 wirelesslycommunicates with the receiver 40. In certain embodiments, the receiver40 includes at least one of an RF receiver, an audio speaker, and aWi-Fi module which is configured to wirelessly transmit data (e.g., asan RF signal) received from the pusher 26.

Turning to FIG. 4, the same illustrates pusher 26 in a partiallyexploded view. Pusher 26 includes an outer housing 76 that has beenpartially removed to reveal the interior componentry of pusher 26.Pusher 26 carries a coil spring 80. Coil spring 80 is mounted on aspring drum 82. Spring drum 82 is rotatable about a shaft 84 to allow,in specific embodiments, an uncoiled portion of coil spring 80 to bepaid out or retracted through an opening 86 formed in housing 76.

As can be seen in FIG. 4, spring drum 82 includes gear teeth 90 a, 90 bformed at opposed peripheral side edges of spring drum 82. Gear teeth 90a are used to repeatedly actuate a portion of direction sensor 64 asdescribed below. Gear teeth 90 b mesh with a sensing gear 92 ofincremental distance sensor 66 as shown. As described in greater detailbelow, sensing gear 92 includes a slotted disc 94 mounted to or formedintegrally with sensing gear 92.

Slotted disc 94 includes a plurality of slots 96 formed in a peripheralregion thereof as shown. These slots successively block a beam of lightof incremental distance sensor 66 as sensing gear 92 rotates. Thisaction creates successive light pulses which are detected by incrementaldistance sensor 66 and used to measure the distance traveled by pusher26 with a high resolution.

Each of the spring drum sensor 62, direction sensor 64, and incrementaldistance sensor 66 are coupled to a printed circuit board (PCB) 98 asshown to achieve the topology illustrated in FIG. 3. Additionally, areset control 102 which may be a button, switch, or dial, and thresholddistance control 104 are also coupled to PCB 98 to achieve thefunctionality described herein. Thus, embodiments of the pusher 26include the reset control 102 to set a zero position for the controller60, the zero position indicating that no merchandise is contained in thepusher assembly 22 such that the pusher 26 is at the front end of thetrack 28.

With reference to FIG. 5, when a portion of coil spring 80 is uncoiledand then is recoiled onto spring drum 82 by moving in direction 120,spring drum 82 rotates in direction 110 as shown. Movement of coilspring 80 in direction 120 is indicative of pusher 26 moving toward thefront of shelf 24 (see FIGS. 1, 2), i.e., is indicative to a product orproducts 42 being removed from display 20.

Due to the contact between spring drum 82 and sensing gear 92, thiscauses sensing gear 92 and its associated slotted disc 94 to rotate indirection 116 as shown. Conversely, movement of spring 80 in direction122 causes spring drum 82 to rotate in direction 112 as shown. Movementof coil spring 80 in direction 122 is indicative to usher 26 movingtoward the back of shelf 24 (see FIGS. 1, 2), i.e., is indicative ofproduct or products 42 being restocked into display 20. This in turncauses sensing gear 92 and slotted disc 94 to rotate in direction 114.

Turning now to FIG. 6, the operation of spring drum sensor 62 anddirection sensor 64 will be described in greater detail. Turning firstto spring drum sensor 62, the same includes a pair of opposed electricalcontacts 134, 136 as shown. Contact 134 is coupled to PCB 98 by way of ahousing 130. Similarly, contact 136 is coupled via a housing 132 to PCB98. Each electrical contact 134, 136 is generally flexible so that itmay readily move into and out of contact with the other contact.

As spring drum 82 rotates, a radially protruding tab 140 mounted to ahub 142 of spring drum 82 rotates as well. Upon each full revolution ofspring drum 82, tab 140 will bias contacts 134, 136 together. In theillustration of FIG. 6, spring drum 82 is rotating in direction 110, andthus tab 140 has biased contact 134 into contact with 136.

Controller 60 is operable to detect when electrical contacts 134, 136are in contact with one another, and records this information. Twosuccessive contacts between electrical contacts 134, 136 signifies onefull revolution of spring drum 82, which corresponds to a linearmovement of spring 80 and hence a linear movement of pusher 26.

Direction sensor 64 is used to direction the rotational direction ofspring drum 82 as movement is detected. Indeed, while two successivecontacts of electrical contacts 134, 136 provides an indication of alinear distance moved by pusher 26, these contacts do not provide anindication of which direction pusher 26 was moving during that time. Theoperation of direction sensor 64 is thus used to correlate a directionwith the movement detected.

Direction sensor 64 includes a first electrical contact 150, a secondelectrical contact 152, and a common electrical contact 154 interposedbetween first and second electrical contacts. Common electrical contact154 is resiliently movable into contact with either one of first orsecond electrical contacts 150, 152. Each of these contacts, 150, 152,and 154 are insulated from one another via a housing 156, and coupled toPCB 98.

For example, as spring drum 82 rotates in direction 110 as shown, adistal end of common electrical contact 154 is intermittently butrepeatedly contacted by the teeth of gear teeth 90 a, and repeatedlybrought into contact with first electrical contact 150. Conversely, whenspring drum 82 rotates in direction 112 (see FIG. 5), common electricalcontact 154 is repeatedly brought into contact with second electricalcontact 152. Controller 60 is operable to recognize that successivecontact between common electrical contact 154 and first electricalcontact 150 is indicative of pusher 26 moving toward the front of shelf24 (see e.g., FIGS. 1, 2). Conversely, controller 60 is also operable torecognize that successive contact between common electrical contact 154and second electrical contact 152 is indicative of pusher 26 movingtoward the rear of shelf 24 (see e.g., FIGS. 1, 2).

It will be recognized, however, that spring drum sensor 62 can detectonly large-scale movement of pusher. As used herein, “large-scalemovement” means movement of pusher 26 which corresponds to one fullrevolution of spring drum 82. In order to determine incremental movementof pusher 26, incremental distance sensor 66 is employed. As usedherein, “incremental movement” of pusher 26 means movement that is lessthan a large-scale movement. Indeed, in a single movement cycle, i.e.,an uninterrupted movement of pusher 26, the same may move some distanceprior to and/or after the two successive contacts of contacts 134, 136that signifies one large-scale movement. Incremental distance sensor 66is thus used to determine this additional distance.

With reference to FIGS. 7 and 8, incremental distance sensor 66 includesthe aforementioned sensing gear 92 and slotted disc 94, which arerotatable about an axis defined by shaft 144 upon a correspondingrotation in spring drum 82. Incremental distance sensor 66 also includesa light sensor arrangement comprising a light emitter 160 aimed at alight receiver 162 for detecting the presence or absence of a beam oflight emitted from emitter 160. Emitter 160 and receiver 162 are mountedto a housing 164 as shown. Housing 164 includes a slot 164 which definesa sensing region. The peripheral region of slotted disc 94 rotatesthrough this sensing region. The slots 96 thereby successively interruptthe beam of light from emitter 160.

As a result, receiver 162 detects pulses of light. Due to the equallyspaced and regular arrangement of slots 96, these pulses thus eachcorrespond to a small linear movement of pusher 26. Put differently, thepulses can be summed at controller 60 so as to determine a totaldistance moved by pusher 26 in any given movement cycle. Due to thisvery fine measurement, the resolution of distance measurement of pusher26 is relatively high. As such, even very minor movements of pusher 26corresponding for example very thin products 42 being removed can bedetected. It will be recognized that incremental distance sensor 66 thusfunctions as a rotary encoder used for linear distance measurement.

The following provides an example of the distance measurementfunctionality of pusher 26. In this particular example, the gear ratiobetween spring drum 82 and sensing gear 92 is 1:4. Spring drum 82 has anouter diameter of 13.5 mm. As a result, one full revolution of springdrum 82 as detected by spring drum sensor 62 corresponds to 84.8 mm(i.e., 2*pi*13.5). Also in this example, there are 40 slots 96 formed onslotted disc 94. As such, one full revolution of slotted disc 94generates 40 light pulses. Due to the aforementioned 1:4 gear ratio, onefull revolution of spring drum 82 will cause four full revolutions ofslotted disc 94, and hence 160 light pulses for every one fullrevolution of spring drum 82. Dividing the circumference of spring drum82 by this total number of pulses, (i.e., 84.8 mm/160 pulses) each pulsetherefor corresponds to 0.53 mm of linear movement.

For the purposes of this example, it will be assumed that pusher 26 hasmoved 200 mm in a movement cycle. From start to finish in this movementcycle, pusher 26 will first move some distance prior to contacts 134,136 making their first contact. These contacts 134, 136 will then make asecond contact after spring drum 82 completes a full revolution (i.e., arevolution as measured by a first and a second contact of contacts 134,136). Contacts 134, 136 will then make a third contact after anotherfull revolution of spring drum 82 (i.e., as measured by the thirdcontact of contacts 134, 136 occurring after the aforementioned secondcontact). Pusher will then move some distance after this third contact.

During the aforementioned movement, incremental distance sensor 66sensed pulses of light. Assume for this example 15 pulses were detectedprior to the first contact of contacts 134, 136, this distance portioncorrelates to a distance of 15*0.53 mm or 7.95 mm. Also assume for thisexample that 42 pulses were detected after the third contact of contacts134, 136, this distance portion correlates to a distance of 42*0.53 mmor 22.26 mm. Also, as already mentioned, three total contact eventsbetween contacts 134, 136 were detected, which amounts to two fullrevolutions of spring drum 82, correlating to a distance portion of169.6 mm. Summing the aforementioned distance portions, a total traveldistance of approximately 200 mm has been detected.

In terms of loss prevention, the user can set an alarm thresholddistance using threshold distance control 104 which may be a button,switch, dial, or any similarly suitable means for setting the alarmthreshold distance. This threshold distance is the distance in amovement cycle observed by pusher 26 in which an alarm will begenerated. The pusher 26 may include a control, similar to the thresholddistance control 104, which allows the user to adjust a time periodduring which the alarm threshold distance must be exceeded in order togenerate the alarm. All distance measurements and alarm conditions canbe transmitted to receiver 40. Further, receiver 40 may be incommunication with or embody inventory management software such that inaddition to loss prevention, each pusher assembly 22 can alsocommunicate information regarding its stock status, etc. As such,receiver 40 may incorporate or be in communication with a user interfacefor inputting an alarm threshold and/or a product depth as discussedbelow. In general, the capability of high-resolution distancemeasurement can be used for anti-theft and inventory managementfunctions.

Referring back momentarily to FIG. 1, in terms of inventory management,the data communicated by each pusher 26 is also associated with a uniquelocation identifier for each pusher. This enables the inventorymanagement software to differentiate between the various pushers 26 inthe system, and monitor the inventory of each. As such, a user can alsodefine a product size for, i.e., depth, for one item of product in thepusher assembly 22. The pusher 26 may then correlate the locally atcontroller 60, or remotely at receiver 40 or any inventory managementsoftware integrated with or in communication with receiver 40, thedistance it has traveled to a number of products removed from pusherassembly 22. As an example, a user may indicate that a single item has aone-inch depth. A movement of ten inches, therefore, amounts to tenproducts being removed. A user may set this minimum product depth usingthreshold distance control 104, or they may set it at receiver 40 or theinventory management software embedded in or associated therewith. Thethreshold distance control 104 may be a dial, button, switch, or anysuitable means for setting the minimum product depth.

Turning now to FIG. 9, the same illustrates the basic control logic ofeach pusher assembly 22. Starting at step 200, each pusher 26 must be“zeroed” by activating its reset control, such as a switch, dial, orbutton, when no product 42 is loaded therein, i.e., when coil spring 80has drawn pusher 26 as close as is possible to the front of shelf 24.This is recorded at step 202 as the zero position. Thereafter, pusher 26remains in sleep mode at step 204 until motion is detected at 206. Uponthis detection, pusher 26 exits sleeps mode and monitors and calculatesthe distance it has moved at step 210 using the sensor arrangementdescribed above.

At step 212 a determination is also made as to whether pusher 26 ismoving up (i.e., toward the front of shelf 24) or down (i.e., toward therear of shelf 24). If moving down, the process loops back to step 204.If moving up, the process continues to step 214 where a determination ofwhether the fist rotation marker (i.e., a contact of contacts 134, 136)has been detected. If yes, this information is updated at step 216.After step 216, or if no contact of contacts 134, 136 is detected, theprocess moves on to step 218 and records the distance moved forward.This distance is then analyzed at step 220 to see if it is greater thana first threshold, i.e., a “beep” threshold where only a temporary alarmis generated. If it is not greater than this threshold, at step 260transmitter 72 then sends RF data corresponding to the original positionof pusher 26, the distance pusher 26 moved, the direction pusher 26moved, and an alarm status.

If, however, at step 220 the distance moved is such that the temporaryalarm should be generated, at check is performed at step 222 to confirmwhether or not the distance moved is great enough to warrant a fullalarm. If yes, at step 226 the alarm status is saved and an alarm offive seconds in duration is generated at step 228. If, at step 222 it isdetermined that the alarm threshold has not been met, then an additionalcheck at step 224 is performed to determine whether the threshold atstep 220 has been exceeded within a time period of ten seconds. If no,the temporary alarm status is saved at step 230 and only the temporaryalarm is generated at step 232. At the end of either of steps 228 or232, RF information is sent at step 260.

If the check at step 220 is no, or if either of steps 228 or 232 arecompleted, the process then proceeds to step 240, to determine whetherthe pusher is at its previously-set zero position. If yes, then theforegoing steps are repeated as necessary upon movement of pusher 26. Ifnot, the process moves onto step 242 where pusher 26 returns to sleepmode. Pusher 26 exits sleep mode at step 246 and monitors and calculatesthe distance it has moved at step 248. A determination at step 250 isconducted to determine whether the pusher has moved up or down in thesame manner as described above relative to step 212. If moving up, theprocess proceeds to step 218 and continues as described above. If movingdown, this distance is recorded at step 252. A determination is thenmade at step 254 as to whether pusher 26 has returned to its zeroposition. If so, it is recorded at step 256 that the pusher is at itszero position, and the process continues to step 220. If not, nothing isrecorded, and the process continues to step 220.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

What is claimed is:
 1. A retail merchandise pusher configured forsliding along a track of a pusher assembly, the pusher assemblymountable to a retail merchandise shelf, the pusher comprising: ahousing; a spring drum rotatably mounted within the housing; a coilspring mounted to the spring drum, the coil spring coilable anduncoilable upon rotation of the spring drum; and a controller coupled toa sensor arrangement carried within the housing, the sensor arrangementcomprising: a spring drum sensor for detecting rotation of the springdrum; a direction sensor for detecting a direction of rotation of thespring drum; and an incremental distance sensor for detecting anincremental movement of the pusher; wherein the controller is configuredto calculate, based on data from the sensor arrangement, a totaldistance and direction of travel by the pusher, and to generate an alarmwhen the pusher travels more than a threshold distance within apredetermined period of time.
 2. The retail merchandise pusher of claim1, wherein the alarm is at least one of a visual, audible, or RF signal.3. The retail merchandise pusher of claim 2, wherein the controller iscoupled to an output device disposed in the housing, the output deviceconfigured to produce the alarm as a visual or audible signal.
 4. Theretail merchandise pusher of claim 1, wherein the controller is coupledto a transmitter disposed in the housing, the transmitter configured towirelessly transmit data to a remote receiver, the data including atleast one of an alarm status, and the total distance and direction oftravel by the pusher.
 5. The retail merchandise pusher of claim 4,wherein the controller is configured to transmit information, based ondata from the sensor arrangement, wherein the information includes aninventory status for the pusher assembly.
 6. The retail merchandisepusher of claim 1, wherein the controller comprises a microprocessor. 7.The retail merchandise pusher of claim 1, wherein the direction sensorincludes a first electrical contact, a common electrical contact, and asecond electrical contact, the common electrical contact interposedbetween the first electrical contact and the second electrical contact.8. The retail merchandise pusher of claim 7, wherein a distal end ofcommon electrical contact is intermittently in contact with gear teethformed on an outer periphery of the spring drum such that the commonelectrical contact is biased by the gear teeth into contact with thefirst electrical contact when the spring drum rotates in a firstdirection, and biased by the gear teeth into contact with the secondelectrical contact when the spring drum rotates in a second rotationaldirection opposite the first rotational direction.
 9. The retailmerchandise pusher of claim 1, wherein the incremental distance sensorincludes a sensing gear in contact with the spring drum, and a slotteddisc mounted to the sensing gear, the incremental distance sensorfurther comprising a light sensor arrangement configured to produce anddetect a beam of light.
 10. The retail merchandise pusher of claim 9,wherein a peripheral region of the slotted disc is movable through asensing region through which the beam of light extends, wherein theperipheral region includes a plurality of slots formed therein, whereinthe plurality of slots sequentially pass through the sensing region asthe sensing gear rotates such that the beam of light alternately passesthrough and is blocked by the plurality of slots.
 11. The retailmerchandise pusher of claim 10, wherein the light sensor arrangementincludes a light emitter located on a first side of the slotted disc,and a light sensor located on a second side of the slotted disc oppositethe first side, the light sensor arranged to detect the beam of lightemitted by the light emitter.
 12. The retail merchandise pusher of claim11, wherein the light emitter is arranged to emit the beam of light suchthat it is perpendicular to a plane of rotation defined by the slotteddisc.
 13. The retail merchandise pusher of claim 1, wherein the coilspring is configured to bias the housing toward one end of the track.14. The retail merchandise pusher of claim 1, wherein the pusher isconfigured to permit a user to set or adjust at least one of thethreshold distance and the predetermined period of time.
 15. The retailmerchandise pusher of claim 1, wherein the pusher includes a resetcontrol to set a zero position for the controller, the zero positionindicating that no merchandise is contained in the pusher assembly suchthat the pusher is at an end of the track.
 16. A pusher assemblyconfigured for mounting to a retail shelf, the shelf having a front anda back, wherein retail merchandise situated near the front of the shelfis removable from the pusher assembly, the pusher assembly comprising: atrack; a pusher mounted to the track, the pusher slidable toward andaway from the front of the shelf, the pusher comprising a controllercoupled to a sensor arrangement for detecting movement and a directionof travel by the pusher, the controller configured to calculate, basedon data from the sensor arrangement, a total distance traveled by thepusher along the track, the controller further configured to generate analarm when the pusher travels more than a threshold distance within apredetermined period of time.
 17. The pusher assembly of claim 16,wherein the sensor arrangement includes a spring drum sensor, adirection sensor, and an incremental distance sensor.
 18. The pusherassembly of claim 17, wherein the direction sensor includes a firstelectrical contact, a common electrical contact, and a second electricalcontact, the common electrical contact interposed between the firstelectrical contact and the second electrical contact.
 19. The pusherassembly of claim 17, wherein the incremental distance sensor includes asensing gear in contact with the spring drum the gear including aslotted disc mounted to the gear, the incremental distance sensorfurther comprising a light sensor arrangement configured to produce anddetect a beam of light.
 20. The pusher assembly of claim 16, wherein thealarm is at least one of a visual, audible, or RF signal, and thecontroller is coupled to a transmitter configured to wirelessly transmitdata to a remote receiver, the data including at least one of an alarmstatus, and the total distance and direction of travel by the pusher.21. The pusher assembly of claim 16, wherein the pusher is configured topermit a user to set or adjust at least one of the threshold distanceand the predetermined period of time, and includes a reset control toset a zero position for the controller, the zero position indicatingthat no merchandise is contained in the pusher assembly such that thepusher is at an end of the track.
 22. The pusher assembly of claim 16,wherein the controller is configured to provide, based on data from thesensor arrangement, an inventory status of the pusher assembly.
 23. Aretail merchandise display system for self-facing retail merchandise,the retail merchandise display comprising: a shelf; at least one pusherassembly mounted to the shelf, the at least one pusher assemblycomprising: a track; a pusher slidable along the track, the pusherassembly comprising a controller coupled to a sensor arrangement, thecontroller configured to calculate, based on data from the sensorarrangement, a large-scale movement of the pusher, and an incrementalmovement by the pusher, wherein the controller is configured to generatea local alarm when a total distance traveled by the pusher, the totaldistance being equal to a sum of the large-scale movement and theincremental movement, is greater or equal to a predefined distance; andthe pusher including a transmitter operable to wirelessly communicatethe total distance traveled by the pusher; and a receiver, remotelylocated from the pusher, is configured to receive a wireless signal fromthe transmitter, and configured to generate a remote alarm in concertwith the local alarm.
 24. The retail merchandise display system of claim23, wherein the local and remote alarms are at least one of visual oraudible alarms.
 25. The retail merchandise display system of claim 23,wherein the at least one pusher assembly includes a plurality of pusherassemblies, wherein each one of the plurality of pusher assemblieswirelessly communicate with the receiver.
 26. The retail merchandisedisplay system of claim 23, wherein the receiver includes an RFreceiver, an audio speaker, and a Wi-Fi module configured to transmitdata received from the pusher.
 27. The retail merchandise system ofclaim 23, wherein the wireless signal is an RF signal.
 28. The retailmerchandise system of claim 23, wherein the sensor arrangement includesa spring drum sensor, a direction sensor, and an incremental distancesensor.
 29. The retail merchandise display system of claim 23, whereinthe receiver is configured to transmit data received from the pusher toa computer or mobile device, wherein the data allows the computer ormobile device to display information regarding the pusher assembly. 30.The retail merchandise display system of claim 29, wherein theinformation regarding the pusher assembly includes at least one of analarm status, and inventory status, and a position of the pusher.